Coil winding apparatus



July 16, 1968 E HASLAU 3,392,760

COIL WINDING APPARATUS Filed May 23, 1966 5 Sheets-Sheet 1 INVENTOR.

fierrdvuu BY July 16, 1968 H. E. HASLAU COIL WINDING APPARATUS 5 Sheets-Shet 2 Filed May 23, 1966 INVENTOR.

July 16, 1968 H. E. HASLAU COIL WINDING APPARATUS Filed May 25, 1966 5 Sheets-Sheet 5 INVE TOR. %e:r 4241/ H. E- HASLAU CO IL- WINDING APPARATUS July 16, 1968 5 Sheets-Sheet 4 Filed May 23, 1966 INVENTOR fierr 44/9/4324 BY {fuzzy July 16, 1968 H E HASLAU COIL WINDING APPARATUS 5 Sheets-Sheet 5 Flled May 23, 1966 INVENTOR. #4144 I if.

United States Patent 3,392,760 COIL WINDING APPARATUS Horst E. Haslau, Cherry Hill, N.J., assignor to Radio Corporation of America, a corporation of Delaware Filed May 23, 1966, Ser. No. 552,078 Claims. (Cl. 14092.2)

This invention relates to apparatus for winding oddshaped coils and particularly to a machine for winding saddle type coils for electron beam deflection yokes.

Deflection yokes employed with color television picture tubes of the shadow mask type comprise a pair of horizontal and a pair of vertical saddle type coils. Each coil has two spaced groups of active side conductors extending generally along the longitudinal axis of the tube and spaced from one another circumferentially of the tubes. The side conductors are joined at their ends by end conductors extending transversely of the tube. The side conductors follow the contour of the picture tube which flares from the neck section to the bulb section. The opening defined by the two spaced groups of side conductors and their associated front and rear end turns is generally termed a window.

Wide angle beam deflection yokes of the character described not only must deflect the electron beams through the required angles to cover the entire screen area, but must do so with a minimum of raster distortion, astigmatism and coma. The capability of a yoke to accomplish such ends is determined by the location of the side coil conductors in their respective groups. In order to satisfy all of the enumerated requirements of a yoke with a single saddle type coil, the optimum distribution of side conductors would be one in which the greater number of them is located in the portion remote from the window at the front and rear ends of the coil and in the portion adjacent to the window in the intermediate section of the coil. Such distribution of the side conductors of the saddle type yoke coils is not feasible with presently know winding techniques and tools.

A deflection yoke has ben designed which has a varied distribution of the active coil conductors such that the distribution is approximately uniform at the rear of the yoke and is progressively changed toward the front of the yoke where a greater number of conductors are located remote from the coil windows than are disposed adjacent the windows. Additionally, each of the side coil conductors extending from the rear to the front of the yoke lies substantially along a geodesic line following the curvature of the flared bulb section of the picture tube. The term geodesic line, as used in the following description and in the claims, is intended to have its usually accepted meaning, viz., the shortest line lying on a given surface and connecting two given points on that surface.

Saddle type deflection yoke coils customarily are wound by machines embodying the teachings of US. Patent No. 2,448,672 granted to H. V. Knauf, In, Sept. 7, 1948. Present day coils have flared shapes and varied conductor distributions which are achieved by suitable shaping the arbors upon which they are wound. As in the Knauf patent, these arbors comprise male and female members which are mated so as to form a cavity therebetween in which to receive the coil conductors. The two side pockets of the cavity receive the longitudinal active conductors and the two end pockets of the cavity receive the lateral inactive conductors which join the active conductors in the side pockets. The spacing between the walls of the side pockets of the cavity usually is varied in order to achieve the desired distribution of the longitudinal active coil conductors. It also is customary to provide a uniform spacing of the walls of the end pockets of the cavity because the transverse inacive coil conductors re- "ice ceived therein, serve no function in the deflection of the electron beam and, hence, their distribution is immaterial.

It has not been possibe, however, to wind flared yoke coils by the techniques and tools described and have all of the longitudinal conductors lie along the curvature of the flared surface in geodesic lines. The longitudinal conductors which are spaced somewhat from the coil window tend to bow inwardly toward the window, thus departing from the geodesic lines. It has been determined that this undesired conductor bowing results from the accumulation of the transverse conductors in those portions of the end pockets of the arbor cavity adjacent to the coil window.

It, therefore, is an object of this invention to provide an improved winding arbor upon which may be wound a flared deflection coil having substantially all of the longitudinal active conductors lying along geodesic lines following the flared curvature.

In accordance with the invention, part of at least one of the end pockets of the arbor cavity is made narrower than the rest of the pocket. By properly graduating the extent of such narrower portions within the end pocket, the tendency for the longitudinal conductors to bow as they merge into transverse conductors is minimized with the result that substantially all of the longitudinal conductors lie along geodesic lines.

For a more complete disclosure of the invention, reference may be had to the following description which is given in conjunction with the accompanying drawings, of which:

FIGURE 1 is a top view of the arbor with the male and female members in mated position for winding a coil;

FIGURE 2 is a side view of the arbor coil in winding position;

FIGURE 3 is an opened view of the arbor showing the general configuration and arrangement of the male and female members;

FIGURE 4 is an assembled view of the arbor showing additional details to those shown in FIGURE 1;

FIGURE 5 is a sectional view of the assembled arbor taken on the line 5-5 of FIGURE 4;

FIGURE 6 is a side view, partly in section, of the male member of the arbor;

FIGURE 7 is a side view of a deflection yoke coil Wound by the arbor shown in FIGURES 1-6;

FIGURE 8 is a bottom or inside view of the coil of FIGURE 7; and

FIGURE 9 is a large-end view of the coil of FIGURES 7 and 8.

As shown in FIGURES l, 2 and 3, the arbor comprises a female coil-forming member 15 which is supported by a mounting plate 16 and a male coil-forming member 17 supported on a mounting plate 18. A spindle 19 is rigidly attached to the male member mounting plate 18 and has an extension 20 running through the male member and ending in a threaded portion 21 (FIGURE 3). The female member 15 is provided with a centrally located hole 22 into which the threaded end 21 of the spindle extension 20 is inserted for engagement with a nut 23 held captive in the female member (FIGURE 4) and operative to join the female and male members 15 and 17 as shown in FIGURES l and 2. The spindle 19 is adapted to be rotated by suitable means (not shown) so as to impart a rotating motion to the mated female and male members 15 and 17.

As shown in FIGURE 3, the female member 15 comprises a block 24 having a flat front-end surface 25 and a similar flat rear-end surface 26 which is parallel with the front-end surface 25. This member also is provided with a centrally located window block 27 on either side of which is a pair of spaced recesses 28 and 29. Each of the recesses is concavely curved so as to conform substantially with the configuration of the merging neck and bulb sections of the cathode ray tube with which the deflection coil is to be used. The window block 27 has front and rear ends 31 and 32, respectively, which are co-planar with the respective front and rear surfaces 25 and 26 of the block 24. The window block 27 also has curved sides 33 and 34, the curvature being such that the intersections of the window block side sections 33 and 34 with the respcctive recesses 28 and 29 define geodesic lines along the curved contours of the recesses.

The female member 15 also is provided with a pair of side wire-deflecting curved rods 35 and 36, one end of each of these rods being attached to the main block 24 on opposite sides thereof, and the other end of each of the rods being attached to the mounting plate 16 at spaced points adjacent the periphery thereof. The purpose of such rods is to deflect, or guide the wire into the recesses 28 and 29 during the coil winding operation in a manner to be described. The female member 15 also is provided with a wire-starting terminal 37 and a wire-finishing terminal 38. One end of the wire is anchored to the start terminal 37 at the beginning of a winding operation and the other end of the wire comprising the coil is attached to the finishing terminal 38 at the termination of a winding operation. Both of the terminals 37 and 38 are electrically insulated from the mounting plate 16.

The male coil-forming member 17, shown in FIGURE 3, includes a pair of spaced body sections 39 and 41 both of which have convexly curved configurations conforming, substantially, to the configuration of the merging neck end bulb portions of the cathode ray tube with which the coil is to be used. The body sections 39 and 41 are separated by a window opening 42 which has a configuration matching that of the window block 27 of the female member 15. The dimensions of the window opening 42 are only slightly greater than the outside dimensions of the window block 27 so that the window block may be snugly fitted into the opening 42 when the male and female members of the winding arbor are joined.

The male coil-forming member 17 also has front and rear flanges 43 and 44, respectively, which extend radially outwardly from the ends of the body sections 39 and 41 substantially parallel to one another. The internal spacing between the front and rear flanges 43 and 44 is sufficiently greater than the spacing between the front and rear end pockets of the cavity formed by the mated female and male members 15 and 17 to receive the transverse or end conductors of the coil. As shown in FIGURE 3, the front flange 43 is larger than the rear flange 44 in order to conform with the larger flared front end of the coil. The front end flange 43 has a pair of ledges 45 and 46 formed internally, thereof, adjacent to the respective body sections 39 and 41. The purpose of these ledges is to effectively reduce the thickness of portions of the front end pocket formed between the flange 43 and the front end surface 25 of the female member 15.

The male member 17 also is provided with a pair of end wire-deflecting vanes 47 and 48. Each of these vanes is a hollow shell, one end of the outer surface of each of which has a configuration conforming to that of the flange with which it is associated. As shown in FIGURE 3, each vane has an outer curved configuration extending substantially to the periphery of the mounting plate 18 so as to properly guide the wire into the winding cavity of the arbor during rotation of the apparatus. It is to be noted that the vanes 47 and 48 extend radially outwardly, approximately at right angles to the side deflecting rods 35 and 36 of the female member 15.

FIGURES 4, and 6 illustrate the details of the arbor cavity formed between the female and male members 15 and 17 respectively. Side pockets 49 and 51, in which to receive the longitudinal coil conductors, are formed between the female block 24 and the body sections 39 and 4 41 of the male member 17. These side pockets are separated by the window block 27. A rear end pocket 52 is formed between the rear flange 44 and the rear end surface 26 of the female block 24. Likewise, a front end pocket 53 is formed between the front flange 43 and the front end surface 25 of the female block 24.

In winding a saddle type deflection coil on the apparatus described, the start end 54 of the wire 55 is attached to the start terminal 37 as shown in FIGURES 1, 2 and 3. The rotation of the arbor in the direction of the arrow draws the wire 55 under some tension into the cavity from a supply reel (not shown). The step-by-step sequency of the operations may best be followed in FIGURE 3. Assume that the first convolution of the coil starts with the wire 55, being fed in from the bottom of the figure, at the rear end of the recess 28 of the female block 24. As the arbor rotates in the direction of the arrow, the wire is directed by means of the deflecting rod 36 into the recess 28 forming the side pocket 49 against the curved side 33 of the window block 27. After approximately the first of rotation of the arbor, the wire 55 is deflected over the curved outer surface of the large front end deflecting vane 47 until further rotation of the arbor causes the wire to fall over the end of the vane and the front end flange 43 into the front end pocket 53. During the second approximately 90 of arbor rotation, the wire is drawn into the front end pocket. The wire is then intercepted by the front end side deflecting rod 35 by which it is guided into the recess 29 forming the side pocket 51 of the cavity and against the curved side 34 of the window block 27. After approximately the third 90 of rotation of the arbor, the wire 55 is deflected over the curved outer surface of the small rear end deflecting vane 48 until further arbor rotation causes it to fall over the end of the vane and the rear end flange 43 into the rear end pocket 52. The fourth approximately 90 of arbor rotation causes the wire to be drawn into the rear end pocket and the described cycle of operation is repeated.

When the desired number of coil convolu'tions have been formed by continued rotation of the arbor, it is stopped, the finishing end of the wire 55 is served from the supply reel and it is attached to the finish terminal 38. A source of current is connected to the start and finish terminals 37 and 38 and suflicient current is passed through the coil while it is still in the cavity of the arbor to cause the insulating coating of the wire to soften. A forming die 56 then is moved into the side pockets 49 and 51, and the end pockets 52 and 53 of the cavity through appropriate openings (not shown) in the male member mounting plate 17. The configuration of the die 56 conforms to the desired configuration of the outer edges of the coil remote from the window. The die, thus, presses the longitudinal coil conductors together against the window block 27 of the female arbor member 15. The softened wire coatings of adjacent conductors merge with one another and become bonded together when the heating current is removed and the coil cooled as by blowing cold air into the arbor cavity. The coil, when removed from the arbor after separation of the female and male members 15 and 17, thus is quite rigid and is ready for assembly into a deflection yoke.

A deflection yoke coil 57 wound in an arbor embodying the present invention is shown in FIGURES 7, 8 and 9. It comprises two groups of longitudinal side conductors 58 and 59, rear and front end transverse conductors 61 and 62 respectively, and a window 63. The manner in which the present arbor enables the production of a coil in which substantially all of the longitudinal conductors follow geodesic lines will be described with reference to two typical longitudinal conductors 64 and 65, respectively, of side conductor groups 58 and 59 and their interconnecting transverse conductor 66.

It will be recalled from the preceeding description of the coil winding operation that, in the transfer of the Wire from one cavity pocket to another, the wire is intercepted by the deflecting rods, 35 and 36, and the vanes 47 and 48. For this reason, considerable tension is placed on the wire in the reg-ion in which transitions are being made between longitudinal and transverse conductors. In winding arbors of prior design, without the ledges 45 and 46 of FIGURES 3, 4, 5 and 6, this tension became effective at a point C somewhat short of the desired forward ends of typical longitudinal conductors 64 "and 65. As a result of the exertion of the tension at the point C, the flared ends of the conductors 64 and 65 tend to be bent inwardly toward the window 63 and, thus, depart from the desired geodesic lines. This effect is most pronounced at the forward end of the coil, where the flare is greatest and in coil sections most remote from the window 63.

The ledges 45 and 46 narrow the outer portions of the front end pocket 53 s as to effectively extend the pocket outwardly from the window 63, thereby constraining the forward ends of the conductors 64 and 65 to lie farther from the window 63 than in a pocket of uniform width. In the present case, the tension on the wire is mainly effective between points C and D. Point C lies on an arc with center 0 coinciding with the central longitudinal axis of the coil 57. Point D lies on an are having a radius A with center P spaced at a distance F from the center 0. The spacing E between these two arcs is maximum in the coil region remote from the window 63 and minimum in the region adjacent to the window. Thus, the spacing E between points C and D is determined by the offset dimension F and the radius A. As a result of the use of the present invention, the group of front end transverse conductors 62 has a general thickness T and, in the region adjacent to the side longitudinal conductors 58 and 59, has a reduced thickness S which is virtually the same as the thickness V of the adjoining longitudinal conductors. For convenience of reference, the dimensions A, E, F, S and T are applied in FIGURES and 6 to those parts of the coil winding arbor which determine the corresponding dimensions of the coil as shown in FIGURES 7, 8 and 9.

By means of the winding arbor embodying the present invention, a machine following the teaching of the Knauf p'atent may be used to wind deflection yoke coils having a flared configuration and in which the active longitudinal conductors lie substantially along geodesic lines.

It is within the purview of this invention to reduce the thickness of the front end pocket 53 by providing ledges, similar to the ledges 45 and 46, on the front end 25 of the female block 24 or, if desired, by providing ledges on both of the flange 43 and the front end 25 of the female block. Also, the rear end pocket 52 may be provided with a reduced thickness portion by similar means if desired.

What is claimed is:

1. In a winding arbor comprising a pair of male and female members adapted to be mated so as to form a cavity therebetween in which to receive a plurality of convolutions of wire constituting a saddle type coil of an electron beam deflection yoke for a cathode ray tube having a substantially cylindrical neck section housing an electron gun and merging into a flared bulb section housing a luminescent screen,

said female member comprising:

front and rear substantially flat parallel surfaces respectively forming inner walls of front and rear end pockets of said cavity within which to receive the transverse inactive end conductors joining the longitudinal active side conductors of said coil,

a pair of spaced recesses extending between said front and rear surfaces and having respective concavely curved configurations conforming substantially to the merged cylindrical neck and flared bulb sections of said cathode ray tube and respectively forming inner walls of side pockets of said cavity within which to receive the longitudinal active side conductors of said coil, and

a window block located between said spaced recesses and having front and rear ends respectively coplanar with said front and rear parallel surfaces and sides curved such that their intersections with said respective recesses define geodesic lines along the curved contours of said recesses; and

said male member comprising:

a pair of spaced body sections having respective convexly curved configurations substantially conforming to the merged cylindrical neck and flared bulb sections of said cathode ray tube and separated by a window opening having a configuration and dimensions such as to snugly receive said window block and respectively forming outer walls of said side pockets of said cavity,

front and rear flanges extending outwardly from the ends of said body sections substantially parallel to one another at a spacing greater than the spacing between the flat parallel surfaces of said female member and respectively forming outer walls of said front and rear end pockets,

means for reducting the thickness of part of at least one of said end pockets of said cavity so as to constrain substantially all of said longitudinal active conductors to follow geodesic lines.

2. A coil winding arbor as defined in claim 1 wherein:

said thickness reducing means includes a pair of ledges formed on one wall of at least one of said end pockets of said cavity.

3. A coil winding ar-bor as defined in claim 2 wherein:

said pair of ledges is formed on the inside of one of said flanges respectively adjacent to said body sections.

4. A coil winding arbor as defined in claim 3 wherein:

said pair of ledges is formed on the inside of said front flange.

5'. A coil winding arbor as defined in claim 4 wherein:

each of said pair of ledges has a varying width which is a minimum adjacent said window opening and which increases gradually to a maximum adjacent a point on said associated body section remote from said window opening.

References Cited UNITED STATES PATENTS 2,448,672 9/ 1948 Knauf -922 2,496,913 2/ 1950 Grundmann 140-922 2,533,506 12/1950 Richard 140-922 2,565,331 8/1951 Torsch 140-92,2 2,638,943 5/1953 Bugg 140-922 2,780,246 2/ 1957 Steger 140-922 2,824,582 2/ 1958 Reitherman 140-922 2,964,068 12/ 1960 Van Voorst 242-9 3,040,783 6/ 1962 Carson 140-922 3,086,562 4/ 1963 Price 140-922 CHARLES W. LANHAM, Primary Examiner.

E. M. COMBS, Assistant Examiner. 

1. IN A WINDING ARBOR COMPRISING A PAIR OF MALE AND FEMALE MEMBERS ADAPTED TO BE MATED SO AS TO FORM A CAVITY THEREBETWEEN IN WHICH TO RECEIVE A PLURALITY OF CONVOLUTIONS OF WIRE CONSTITUTING A SADDLE TYPE COIL OF AN ELECTRON BEAM DEFLECTION YOKE FOR A CATHODE RAY TUBE HAVING A SUBSTANTIALLY CYLINDRICAL NECK SECTION HOUSING AN ELECTRON GUN AND MERGING INTO A FLARED BULB SECTION HOUSING A LUMINESCENT SCREEN, SAID FEMALE MEMBER COMPRISING: FRONT AND REAR SUBSTANTIALLY FLAT PARALLEL SURFACES RESPECTIVELY FORMING INNER WALLS OF FRONT AND REAR END POCKETS OF SAID CAVITY WITHIN WHICH TO RECEIVE THE TRANSVERSE INACTIVE END CONDUCTORS JOINING THE LONGITUDINAL ACTIVE SIDE CONDUCTORS OF SAID COIL, A PAIR OF SPACED RECESSES EXTENDING BETWEEN SAID FRONT AND REAR SURFACES AND HAVING RESPECTIVE CONCAVELY CURVED CONFIGURATIONS CONFORMING SUBSTANTIALLY TO THE MERGED CYLINDRICAL NECK AND FLARED BULB SECTIONS OF SAID CATHODE RAY TUBE AND RESPECTIVELY FORMING INNER WALLS OF SIDE POCKETS OF SAID CAVITY WITHIN WHICH TO RECEIVE THE LONGITUDINAL ACTIVE SIDE CONDUCTORS OF SAID COIL, AND A WINDOW BLOCK LOCATED BETWEEN SAID SPACED RECESSES AND HAVING FRONT AND REAR ENDS RESPECTIVELY COPLANAR WITH SAID FRONT AND REAR PARALLEL SURFACES AND SIDES CURVED SUCH THAT THEIR INTERSECTIONS WITH SAID RESPECTIVE RECESSES DEFINE GEODESIC LINES ALONG THE CURVED CONTOURS OF SAID RECESSES; AND SAID MALE MEMBER COMPRISING: A PAIR OF SPACED BODY SECTIONS HAVING RESPECTIVE CONVEXLY CURVED CONFIGURATIONS SUBSTANTIALLY CONFORMING TO THE MERGED CYLINDRICAL NECK AND FLARED BULB SECTIONS OF SAID CATHODE RAY TUBE AND SEPARATED BY A WINDOW OPENING HAVING A CONFIGURATION AND DIMENSIONS SUCH AS TO SNUGLY RECEIVE SAID WINDOW BLOCK AND RESPECTIVELY FORMING OUTER WALLS OF SAID SIDE POCKETS OF SAID CAVITY, FRONT AND REAR FLANGES EXTENDING OUTWARDLY FROM THE ENDS OF SAID BODY SECTIONS SUBSTANTIALLY PARALLEL TO ONE ANOTHER AT A SPACING GREATER THAN THE SPACING BETWEN THE FLAT PARALLEL SURFACES OF SAID FEMALE MEMBER AND RESPECTIVELY FORMING OUTER WALLS OF SAID FRONT AND REAR END POCKETS, MEANS FOR REDUCTING THE THICKNESS OF PART OF AT LEAST ONE OF SAID END POCKETS OF SAID CAVITY SO AS TO CONSTRAIN SUBSTANTIALLY ALL OF SAID LONGITUDINAL ACTIVE CONDUCTORS TO FOLLOW GEODESIC LINES. 